Alternator system

Abstract

An improved alternator system for replacing an OEM Ford IAR alternator system. The improved alternator system includes a rectifier with increased heat dissipation qualities and decreased heat generation qualities and configured to maintain secure electrical connections. The alternator system is further configured to provide optimum electrical output by providing the rotor and the stator with additional turns or windings of heavier gauge wire whereby the alternator is capable of inducing a stabilized output current of at least about 52 amperes of current at about 1600 revolutions per minute of the rotor.

What is claimed is:  
     
       1. A rectifier in combination with a Ford IAR alternator having a rotor and a plurality of stator windings housed in a frame, the frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and an internal mounting surface to which the rectifier is mounted and electrically connected to the stator windings, the rectifier comprising: 
       a first plate defining a negative heat sink, the negative heat sink having a plurality of diode receiving openings formed therein;  
       a second plate defining a positive heat sink, the positive heat sink electrically insulated from the negative heat sink and having a plurality of diode receiving openings formed therein;  
       a plurality of negative diodes pressed fit into the openings of the negative heat sink;  
       a plurality of positive diodes pressed fit into the openings of the positive heat sink, each of the positive diodes corresponding with and electrically coupled to one of the negative diodes and electrically connected to one of the stator windings; and  
       a connector assembly including a connector box having a recess adapted to matingly receive a wiring harness, a B+ post having a first end secured to the connector box, a medial portion electrically connected to the positive heat sink, and a second end, and a terminal having a first end electrically connected to the B+ post and a second end including a pair of prongs disposed in the recess of the connector box.  
     
     
       2. The rectifier in combination of  claim 1  wherein each of the negative heat sink and the positive heat sink has a uniform thickness greater than 5 mm. 
     
     
       3. The rectifier in combination of  claim 1  further comprising an insulator positioned between the positive heat sink and the negative heat sink so as to electrically insulate the positive heat sink from the negative heat sink, the insulator having a thickness less than 0.020 mm. 
     
     
       4. The rectifier in combination of  claim 1  wherein the B+ post has a minimum diameter of about five millimeters. 
     
     
       5. The rectifier in combination of  claim 1  wherein the B+ post is dimensioned such that the second end of the B+ post extends out through the frame of the alternator. 
     
     
       6. The rectifier in combination of  claim 5  wherein the second end of the B+ post is threaded. 
     
     
       7. A rectifier in combination with a Ford IAR alternator and a plurality of stator windings housed in a frame, the frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and an internal mounting surface to which the rectifier is mounted and electrically connected to the stator windings, the rectifier comprising: 
       a first plate defining a negative heat sink, the negative heat sink having a plurality of diode receiving openings formed therein and having a uniform thickness greater than 5 mm;  
       a second plate defining a positive heat sink, the positive heat sink having a plurality of diode receiving openings formed therein and having a uniform thickness greater than 5 mm;  
       an insulator positioned between the positive heat sink and the negative heat sink so as to electrically insulate the positive heat sink from the negative heat sink, the insulator having a thickness less than 0.020 mm;  
       a plurality of negative diodes pressed fit into the openings of the negative heat sink;  
       a plurality of positive diodes pressed fit into the openings of the positive heat sink, each of the positive diodes corresponding with and electrically coupled to one of the negative diodes and electrically connected to one of the stator windings; and  
       a connector assembly including a connector box having a recess adapted to matingly receive a wiring harness, a B+ post having a first end secured to the connector box, a medial portion electrically connected to the positive heat sink, and a second end, and a terminal having a first end electrically connected to the B+ post and a second end including a pair of prongs disposed in the recess of the connector box, the B+ post having a minimum diameter of five millimeters.  
     
     
       8. The rectifier in combination of  claim 7  wherein the B+ post is dimensioned such that the second end of the B+ post extends out through the frame of the alternator. 
     
     
       9. The rectifier in combination of  claim 8  wherein the second end of the B+ post is threaded. 
     
     
       10. In a Ford IAR alternator having a rotor and a plurality of stator windings housed in a frame, the frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and an internal mounting surface to which a rectifier is mounted and electrically connected to the stator windings, the rectifier having a first plate defining a negative heat sink, a second plate defining a positive heat sink which is electrically insulated from the negative heat sink, a plurality of negative diodes electrically connected to the negative heat sink, a plurality of positive diodes electrically connected to the positive heat sink and corresponding with and electrically coupled to one of the negative diodes and electrically connected to one of the stator windings, and a connector assembly including a connector box having a recess adapted to matingly receive a wiring harness, a B+ post having one end electrically connected to a pair of prongs disposed in the recess of the connector box and another end electrically connected to the positive heat sink, the improvement comprising: 
       the negative heat sink having a plurality of diode openings in which the negative diodes are pressed fit; and  
       the positive heat sink having a plurality of diode openings in which the positive diodes are pressed fit.  
     
     
       11. The improvement of  claim 10  further comprising: the B+ post having a first end electrically connected to the pair of prongs, an intermediate portion electrically connected to the positive heat sink, and a second end which extends outwardly through the frame. 
     
     
       12. The improvement of  claim 11  wherein at least a portion of the portion of the B+ post extending from the frame is threaded. 
     
     
       13. The improvement of  claim 11  wherein the B+ post has a minimum diameter of about 5 mm. 
     
     
       14. The improvement of  claim 10  further comprising: 
       the B+ post having one portion electrically connected to the pair of prongs and another portion pressed fit with the positive heat sink.  
     
     
       15. The improvement of  claim 14  wherein the B+ post is dimensioned such that a portion of the B+ post extends out through the frame. 
     
     
       16. The improvement of  claim 15  wherein at least a portion of the portion of the B+ post extending from the frame is threaded. 
     
     
       17. The combination of  claim 14  wherein the second end of the B+ post is threaded. 
     
     
       18. The improvement of  claim 10  wherein the B+ post has a minimum diameter of about 5 mm.